A rock wool material, a rock wool product and a method for producing the same

Abstract

The application provides a rock wool material, a rock wool product and a preparation method thereof, and relates to the technical field of building material preparation.The raw material of the rock wool material comprises, in terms of weight parts, 15-25 parts of red mud, 5-10 parts of fly ash residue A extracted for alumina, 10-26 parts of fly ash residue B extracted for alumina, 20-46 parts of kaolinite, 18-28 parts of carbide slag and 5-15 parts of wollastonite; the preparation raw material of the rock wool product comprises the rock wool material, a phenolic resin binder and an adsorbent component.The application efficiently utilizes solid waste, greatly reduces the production cost of the rock wool, the rock wool product prepared has good heat preservation performance and fire resistance, simultaneously reduces environmental pollution, greatly guarantees the health of production workers and further guarantees a good living environment.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of building material preparation, in particular to a rock wool material, a rock wool product and a preparation method thereof. BACKGROUND

[0002] Rock wool, also known as rock wool, is a kind of mineral wool. Natural rocks such as basalt, gabbro, dolomite, iron ore and bauxite are used as main materials. After high-temperature melting of the raw materials, the fibers are formed by high-speed centrifugation of a four-axis centrifuge. A certain amount of binder, dustproof oil and water-repellent agent is sprayed, and then collected by a cotton collector. Through the pendulum method process, the three-dimensional method is used for laying cotton, and then solidified and cut to form rock wool products of different specifications and purposes.

[0003] Rock wool products are often used as thermal insulation materials. However, the existing rock wool is mostly produced by adding dolomite to basalt, which requires a large amount of mountain mining. The mining and blasting processes will affect the environment, damage the topography and ecological environment of the mountain, pose a safety hazard and have a high cost, thereby resulting in a high production cost of rock wool. In addition, the raw materials such as binders added during the processing of the existing rock wool products will produce organic harmful gases such as formaldehyde and benzene, which will harm the health of the production workers. SUMMARY

[0004] Therefore, the present application provides a rock wool material, a rock wool product and a preparation method thereof, so as to improve the thermal insulation performance and flame retardant performance of the rock wool product, reduce the production cost and reduce environmental pollution.

[0005] The present application provides the following technical solutions: a rock wool material, the raw materials of the rock wool material include, by weight:

[0006] 15-25 parts of red mud, 5-10 parts of fly ash extraction alumina residue A, 10-26 parts of fly ash extraction alumina residue B, 20-46 parts of kaolinite, 18-28 parts of calcium carbide slag and 5-15 parts of wollastonite;

[0007] The content of iron oxide in the red mud is less than 3%, and the pH value is 7-9. The content of alumina in the fly ash extraction alumina residue A is less than 5%, and the pH value is 8-10. The main chemical component of the fly ash extraction alumina residue A is active calcium silicate, and the content of the active calcium silicate is 60-70%. The main chemical component of the fly ash extraction alumina residue B is silicon dioxide, and the content of the silicon dioxide is higher than 90%.

[0008] The embodiment of the present application adopts solid waste red mud and fly ash residue for extracting alumina (solid waste for extracting alumina from fly ash) to prepare rock wool, first, the iron oxide of the red mud solid waste is removed, so that the content of the iron oxide in the red mud is less than 3%, then the strong alkali in the red mud is removed, so that the pH value of the red mud is reduced from the original 11-12 to 7-9, so as to ensure that the red mud is a weak alkaline substance. The red mud solid waste of the embodiment of the present application must meet the above two conditions.

[0009] After the fly ash is used to extract alumina, the content of the alumina must be less than 5%, the pH value of the residue solid waste is between 8-10, and the main chemical component of the residue is active calcium silicate, the molecular formula is CaO.mSiO2nH2O, that is, the above-mentioned fly ash residue A for extracting alumina. There is another method for extracting alumina by using the acidity method to obtain the above-mentioned fly ash residue B for extracting alumina, which is mainly composed of silicon dioxide (more than 90%).

[0010] The three kinds of solid waste, that is, the red mud, the fly ash residue A for extracting alumina, and the fly ash residue B for extracting alumina, are used as raw materials to prepare rock wool materials, which not only can greatly reduce the cost, but also is beneficial to the protection of the environment at the same time. Moreover, the use of the fly ash residue for extracting alumina reduces the content of the metal and the metal oxide in the raw material, and the alumina is a good heat-conducting material, so that the extraction of the alumina is beneficial to the improvement of the heat preservation performance of the material.

[0011] According to an embodiment of the present application, the acidity coefficient (SiO2+Al2O3) / (CaO+MgO) of the mixture of the red mud, the fly ash residue A for extracting alumina, the fly ash residue B for extracting alumina, kaolinite, carbide slag, and wollastonite is greater than 1.5.

[0012] The present application also provides a rock wool product, and the preparation raw materials of the rock wool product include the rock wool material as described above, a phenolic resin binder, and an adsorbent component.

[0013] The mass ratio of the rock wool material, the phenolic resin binder, and the adsorbent component is 100:(7-7.5):(3.5-5.0).

[0014] According to an embodiment of the present application, the raw materials of the phenolic resin binder include, by weight:

[0015] Phenolic resin 90-110 parts, expanded perlite 10-20 parts, floating bead 5-15 parts, silane coupling agent KH602 0.1-0.15 parts, alcohol 0.1-0.15 parts, wetting dispersant 0.5-1.0 parts.

[0016] According to an embodiment of the present application, the floating bead is a hollow fly ash.

[0017] According to an embodiment of the present application, the adsorbent component comprises activated carbon adsorbent and organic bentonite adsorbent; the particle size of the activated carbon adsorbent and the organic bentonite adsorbent is not less than 200 mesh, and the interlayer spacing of the organic bentonite adsorbent is 3.5-4.0 nm.

[0018] The rock wool product of the embodiment of the present application uses the following raw materials:

[0019] Fly ash extraction residue A (main component: active calcium silicate), fly ash extraction residue B (main component: silicon dioxide 90% or more, a small amount of calcium oxide and iron oxide), red mud, kaolinite, carbide slag, wollastonite, phenolic resin binder, activated carbon adsorbent, and organic bentonite adsorbent.

[0020] When preparing the rock wool, a thermosetting phenolic resin is also needed to be added as a binder. Since the rock wool is a thermal insulation material, the binder used for preparing the rock wool product must also have thermal insulation performance. In the embodiment of the present application, 15-20% hollow microbeads are added to 100 parts of the binder to improve the thermal insulation performance of the binder. The hollow microbeads are expanded perlite or floating beads. After the expanded perlite and the floating beads are treated with a silane coupling agent KH602, they can be mixed into the phenolic thermosetting binder. The phenolic resin binder releases formaldehyde and phenol gas during use. The activated carbon adsorbent and the organic bentonite adsorbent are used to adsorb the harmful gas and reduce the damage to human health.

[0021] The present application also provides a preparation method of the rock wool product as described above, comprising the following steps:

[0022] Step 1. The red mud, fly ash extraction residue A, fly ash extraction residue B, kaolinite, carbide slag, and wollastonite are mixed and then subjected to a melting treatment under high temperature conditions to prepare the rock wool material.

[0023] Step 2. The rock wool material is subjected to a high-speed centrifugal spinning treatment, and then cooled and shaped to prepare the inorganic cotton.

[0024] Step 3. The phenolic resin binder is sprayed onto the surface of the shaped inorganic cotton according to a mass ratio, and then further shaped.

[0025] Step 4. The adsorbent component is added to the inorganic cotton shaped in step 3 according to a mass ratio, and then subjected to a high-temperature drying through a pendulum method process and a three-dimensional cotton laying method. Finally, the rock wool product is prepared after cutting.

[0026] According to an embodiment of the present application, the process of preparing the rock wool material in step 1 comprises:

[0027] (1) First, the red mud, fly ash extraction of alumina residue A, fly ash extraction of alumina residue B, kaolinite, wollastonite are blended until the mixture is uniform to obtain a premix;

[0028] (2) The carbide slag is put into the electric smelting furnace, the temperature is controlled between 550-600 DEG C, the calcium hydroxide is completely decomposed into calcium oxide and water vapor;

[0029] (3) The premix is put into the electric smelting furnace, the temperature is controlled between 1500-1600 DEG C, the mixture is fully melted in the electric smelting furnace to obtain the rock wool material.

[0030] According to an embodiment of the present application, the preparation process of the phenolic resin adhesive comprises:

[0031] (1) The alcohol and silane coupling agent KH602 are mixed according to the mass ratio of 1:1 to obtain the alcohol solution of silane coupling agent KH602;

[0032] (2) The expanded perlite and floating beads are put into a high stirring device, the alcohol solution of silane coupling agent KH602 is added and stirring is started, and the stirring time is 2-3 minutes;

[0033] (3) The treated expanded perlite and floating beads are taken out and air dried for 1 hour to completely volatilize the alcohol;

[0034] (4) The phenolic resin, wetting dispersant and treated expanded perlite and floating beads are put into the high stirring device again for mixing, the mixing time is 3-5 minutes, and the phenolic resin adhesive is obtained.

[0035] Compared with the prior art, the above at least one technical scheme adopted by the embodiments of the present application can achieve the beneficial effects at least including: the embodiments of the present application adopt multiple solid wastes including red mud, carbide slag, two different specifications of fly ash extraction of alumina residue, floating beads and the like, improve the solid waste utilization rate, reduce environmental pollution, reduce the production cost of rock wool products, and the manufactured rock wool does not produce new pollution to the environment. The rock wool product prepared by the embodiments of the present application has excellent heat preservation performance and flame retardant performance, and the preparation process is safe, can greatly ensure the health of production workers, and further ensure a good living environment. BRIEF DESCRIPTION OF DRAWINGS

[0036] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application, and those skilled in the art can obtain other drawings according to these drawings without creating any creative labor.

[0037] Figure 1 is a schematic diagram of a preparation process of a rock wool product of an embodiment of the present application. DETAILED DESCRIPTION

[0038] The embodiments of the present application will be described in detail below with reference to the drawings.

[0039] The above embodiments of the present application are described by way of example only, and other advantages and effects of the present application will be apparent to those skilled in the art from this disclosure. Of course, the embodiments described are merely a part of embodiments of the present application, and not all of the embodiments. The present application can be implemented or applied in other different specific embodiments, and the details in the specification can be modified or changed based on different views and applications, without departing from the spirit of the present application. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0040] The embodiment of the present application provides a rock wool material, raw materials of the rock wool material include the following by weight parts:

[0041] 15-25 parts of red mud, 5-10 parts of fly ash residue A for extracting alumina, 10-26 parts of fly ash residue B for extracting alumina, 20-46 parts of kaolinite, 18-28 parts of carbide slag, and 5-15 parts of wollastonite; wherein the content of iron oxide in the red mud is less than 3%, and the pH value is 7-9; the content of alumina in the fly ash residue A for extracting alumina is less than 5%, and the pH value is 8-10, and the main chemical component in the fly ash residue A for extracting alumina is active calcium silicate, the content of the active calcium silicate is 60-70%, and the main chemical component in the fly ash residue B for extracting alumina is silicon dioxide, and the content of the silicon dioxide is higher than 90%.

[0042] The embodiment of the present application uses solid waste red mud and fly ash residue for extracting alumina (solid waste for extracting alumina from fly ash) to prepare rock wool, first, the iron oxide of the solid waste red mud is removed, so that the content of iron oxide in the red mud is less than 3%, then the strong alkali in the red mud is removed, so that the pH value of the red mud is reduced from the original 11-12 to 7-9, so as to ensure that the red mud is a weak alkaline substance. The solid waste red mud of the embodiment of the present application must meet the above two conditions.

[0043] The content of alumina in the fly ash after extracting alumina must be less than 5%, the pH value of the residue solid waste is between 8-10, and the main chemical component of the residue is active calcium silicate, molecular formula: CaO.mSiO2nH2O, that is, the fly ash residue A after extracting alumina. There is another fly ash residue B after extracting alumina by using the acidity method.

[0044] The three kinds of solid wastes, namely, red mud, fly ash residue A after extracting alumina and fly ash residue B after extracting alumina, are used as raw materials to prepare rock wool materials, which can greatly reduce the cost, is conducive to environmental protection, and the content of metal and metal oxide in the raw material is reduced by using the fly ash residue after extracting alumina, and the thermal conductivity of the material is improved by extracting alumina.

[0045] The kaolinite and the fly ash residue B after extracting alumina (main component is silicon dioxide) provide the basic raw material silicon dioxide for the production of rock wool, the main chemical component of the calcium carbide residue is calcium hydroxide, which can be decomposed into calcium oxide and water after calcination, and the calcium oxide is also a main raw material for preparing rock wool. The main component of rock wool is silicate, and calcium silicate is the main component. Kaolin provides alumina and silicon dioxide for the preparation of rock wool. The main chemical component in kaolin can improve the flame retardant performance of rock wool and ensure the comprehensive performance of rock wool.

[0046] The role of red mud in the production of rock wool is that red mud is a large solid waste, and red mud contains many chemical components, which can not only help to produce high-quality rock wool, but also can greatly reduce the production cost of rock wool.

[0047] The example also uses calcium carbide residue as one of the raw materials for rock wool, and the calcium carbide residue is a solid waste for industrial preparation of acetylene, and acetylene is an important raw material for preparing polyvinyl chloride.

[0048] The fly ash residue A after extracting alumina (main component is calcium silicate) is the main chemical component of rock wool, which is more than 70% of the composition of rock wool. Silicate has very good insulation, and it also has very high melting point and very low thermal conductivity, so it can greatly improve the aging resistance and durability of rock wool. Calcium is a very important element in rock wool, and calcium exists in the form of calcium silicate, which can increase the stability and durability of rock wool.

[0049] In the production of rock wool, kaolin is used, and the main component of kaolin is silicon dioxide. A fly ash residue after extracting alumina (main component is silicon dioxide) is also used, because silicon dioxide is a very important component of rock wool, which not only improves the insulation of rock wool, but also provides the high temperature resistance of rock wool.

[0050] The raw materials used in the embodiment of the present application are mixed from the chemical substances discussed above, and the raw materials further contain elements such as magnesium, aluminum, potassium, sodium, and iron. The magnesium element has very good insulation performance, heat insulation performance, and fireproof performance. These chemical elements in the rock wool, although not in a large proportion, can improve the performance and function of the rock wool, such as improving the compressive strength, corrosion resistance, and shock resistance of the rock wool.

[0051] The rock wool contains silicates, silicon dioxide, and elements such as calcium, magnesium, aluminum, iron, sodium, and potassium, so that the rock wool has different chemical and physical properties. The rock wool can achieve heat insulation, sound insulation, heat insulation, fireproofing, and other properties. In addition, a certain amount of wollastonite is added to the rock wool, and these raw materials have a certain hydrophobicity. Under the condition of adding organosilicon water-repellent agent, the moisture resistance of the rock wool is also improved.

[0052] The production of the rock wool in the embodiment of the present application must ensure good quality. The acidity coefficient, that is, the ratio of (SiO2+Al2O3) / (CaO+MgO), must be greater than 1.5, and the calcium oxide can be provided by the carbide residue.

[0053] Another embodiment of the present application provides a rock wool product. The preparation raw materials of the rock wool product include the rock wool material as described above, and a phenolic resin adhesive and an adsorbent component. The mass ratio of the rock wool material, the phenolic resin adhesive, and the adsorbent component is 100:(7-7.5):(3.5-5.0).

[0054] In the embodiment, the raw materials of the phenolic resin adhesive include, by weight: phenolic resin 90-110 parts, expanded perlite 10-20 parts, floating bead 5-15 parts, silane coupling agent KH602 0.1-0.15 parts, alcohol 0.1-0.15 parts, and wetting dispersant 0.5-1.0 parts.

[0055] In the embodiment, the floating bead is hollow fly ash. The adsorbent component includes activated carbon adsorbent and organic bentonite adsorbent. The particle size of the activated carbon adsorbent and the organic bentonite adsorbent is not less than 200 mesh, and the interlayer spacing of the organic bentonite adsorbent is 3.5-4.0 nanometers.

[0056] The rock wool product of the embodiment of the present application uses the following raw materials:

[0057] Fly ash extraction of alumina residue A (main component active calcium silicate), fly ash extraction of alumina residue B (main component silicon dioxide 90% or more, a small amount of calcium oxide and iron oxide), red mud, kaolinite, carbide residue, wollastonite, phenolic resin adhesive, activated carbon adsorbent, and organic bentonite adsorbent.

[0058] The phenolic resin adhesive releases formaldehyde and phenol gas during use, and the method has the function of adsorbing organic harmful gas, and after the phenolic resin is sprayed on the rock wool, the adsorption aid is sprayed and adsorbed in the state of the rock wool, the organic bentonite has a layer spacing of 3.5-4.0 nanometers, and the activated carbon, the particles of the two kinds of activated adsorbents are more than 200 meshes, and the finer the particles, the higher the adsorption. Organic bentonite is beneficial to adsorb benzene, toluene and phenol. There are free phenol and benzene in the phenolic resin, and the phenolic resin itself is yellow, and the red-brown color indicates that there is free phenol, and the liquid phenolic resin presents red-brown color, which indicates that there is free phenol. The activated carbon adsorbent and the organic bentonite adsorbent are used to adsorb harmful gas and reduce the damage to human health.

[0059] As shown in Figure 1 The application also provides a preparation method of the rock wool product, comprising the following steps:

[0060] Step 1. The red mud, fly ash extraction alumina residue A, fly ash extraction alumina residue B, kaolinite, carbide slag and wollastonite are mixed and subjected to melting treatment under high temperature conditions to obtain the rock wool material;

[0061] Step 2. The rock wool material is subjected to high-speed centrifugal spinning treatment, and the inorganic cotton is obtained after cooling and setting;

[0062] The high-speed centrifugal spinning treatment is that the raw materials are softened after being subjected to melting treatment in an electric melting furnace, and the molten ash is gradually changed into a filamentous substance by using a high-speed centrifugal machine, and the inorganic cotton is obtained after all the spun filaments are adhered together.

[0063] High-speed air cooling and setting: the shape of the inorganic cotton just produced is not fixed, and a high-speed air blower is used to remove the heat on the surface of the inorganic cotton, so that it is more easily formed.

[0064] Step 3. The phenolic resin adhesive is sprayed on the surface of the inorganic cotton after setting according to the mass ratio, and the inorganic cotton is further set;

[0065] After the inorganic cotton is set, it has certain product performance, and the high-efficiency adhesive is sprayed on the surface again, so that the shape is more fixed.

[0066] Step 4. In the further shaping process of step 3, the inorganic cotton is added with the adsorbent component in a mass ratio, and then dried at high temperature after being laid in a three-dimensional manner by the pendulum method. Finally, the rock wool product is obtained after cutting.

[0067] The adsorption functional additive is added to the rock wool to make the rock wool have the function of adsorbing organic harmful gas. The pendulum method is used to repeatedly increase the pressure of the inorganic cotton, so that the hardness and density of the inorganic cotton continue to increase. High-temperature drying is performed on the rock wool material with high density to evaporate the water in the structure. Finally, the rock wool material is cut into different specifications and sizes to obtain the rock wool board.

[0068] In this embodiment, the process of preparing the rock wool material in step 1 includes:

[0069] (1) First, the red mud, fly ash extraction alumina residue A, fly ash extraction alumina residue B, kaolinite, and wollastonite are blended until the mixture is uniform to obtain a premix;

[0070] (2) The carbide slag is put into an electric smelting furnace, and the temperature is controlled between 550-600℃, so that the calcium hydroxide is completely decomposed into calcium oxide and water vapor;

[0071] (3) The premix is put into the electric smelting furnace, and the temperature is controlled between 1500-1600℃, so that the mixture is fully melted in the electric smelting furnace to obtain the rock wool material.

[0072] In this embodiment, the preparation process of the phenolic resin adhesive includes:

[0073] (1) Mix alcohol and silane coupling agent KH602 in a mass ratio of 1:1 to obtain an alcohol solution of silane coupling agent KH602;

[0074] (2) Put the expanded perlite and floating beads into a high-stirring device, add the alcohol solution of silane coupling agent KH602, and start stirring for 2-3 minutes;

[0075] (3) Take out the treated expanded perlite and floating beads, and air dry for 1 hour to completely evaporate the alcohol;

[0076] (4) Put the powdered phenolic resin 2123 and wetting dispersant 3250 into the high-stirring device again with the treated expanded perlite and floating beads, and mix for 3-5 minutes to obtain the phenolic resin adhesive. The entire operation process is completed at room temperature.

[0077] The fly ash residue for extracting alumina is used to prepare rock wool in the embodiment of the application, and the thermal insulation performance of the rock wool can be improved and the thermal conductivity coefficient of the rock wool can be reduced because alumina is a good thermal conductive metal oxide material.

[0078] The new solid waste calcium carbide slag is used as the raw material in the embodiment of the application, and the main chemical component of the calcium carbide slag is calcium hydroxide. The calcium carbide slag is the waste residue with calcium hydroxide as the main component after the calcium carbide is hydrolyzed to obtain acetylene gas. The calcium carbide slag is used to adjust the acidity coefficient of the rock wool product.

[0079] The solid waste is used in large quantities in the embodiment of the application, and not only the red mud and the calcium carbide slag are used, but also two kinds of fly ash residue for extracting alumina and fly ash beads are used. Five kinds of solid waste are used, and the amount of the solid waste is between 50-70%.

[0080] The expanded perlite and the fly ash beads are added in the adhesive phenolic resin used in the rock wool product in the embodiment of the application, so that the bonding performance between the rock wool is ensured, the thermal insulation performance of the product is improved, and the cost of the adhesive is reduced. The fly ash beads are hollow fly ash.

[0081] The phenolic resin adhesive can release harmful gases such as formaldehyde and phenol, and the release speed is relatively slow, the release time is very long, and the harmful gases have a great harm to people. Especially when the phenolic resin is heat cured, a large amount of unpleasant odor is generated. The adsorbent composed of the new material activated carbon and the organic intercalated bentonite DK4 is used to adsorb and treat the organic harmful gas in the embodiment of the application. The health of the production workers can be ensured to a great extent, and the living environment can be ensured to be good.

[0082] The rock wool is prepared by using the solid waste in the embodiment of the application, the cost is low, the environment can be improved, the environmental pollution can be reduced, and new pollution to the environment can not be caused.

[0083] Next, the embodiment of the application is further described.

[0084] Embodiment 1

[0085] The raw material of the rock wool material in the embodiment 1 includes the following components by weight:

[0086] The red mud is 19 parts, the fly ash residue A for extracting alumina is 6 parts, the fly ash residue B for extracting alumina is 10 parts, the kaolinite is 41 parts, the calcium carbide slag is 21 parts, and the wollastonite is 8 parts.

[0087] Embodiment 2

[0088] The raw material of the rock wool material in the embodiment 2 includes the following components by weight:

[0089] Red mud 20 parts, fly ash extraction of alumina residue A 7 parts, fly ash extraction of alumina residue B 20 parts, kaolinite 25 parts, carbide slag 26 parts, wollastonite 12 parts.

[0090] Example 3

[0091] A rock wool material of the present embodiment 3 comprises, by weight parts:

[0092] Red mud 22 parts, fly ash extraction of alumina residue A 10 parts, fly ash extraction of alumina residue B 14 parts, kaolinite 28 parts, carbide slag 17 parts, wollastonite 9 parts.

[0093] The rock wool material prepared by the raw material components of examples 1-3 is subjected to performance testing, and the testing data is shown in Tables 1-3.

[0094] Table 1: Example 1 testing data:

[0095] No. Test item Standard requirement Inspection result 1 Thermal conductivity / W / (m·K) ≤0.040 0.037 2 Volume water absorption ≤5.0 4.2 3 Acidity coefficient ≥1.8 1.86 4 Compressive strength ≥40 46 5 Tensile strength perpendicular to the surface ≥10 12

[0096] Table 2: Example 2 testing data:

[0097] No. Test item Standard requirement Inspection result 1 Thermal conductivity / W / (m·K) ≤0.040 0.039 2 Volume water absorption ≤5.0 3.9 3 Acidity coefficient ≥1.8 1.90 4 Compressive strength ≥40 43 5 Tensile strength perpendicular to the surface ≥10 11

[0098] Table 3: Example 3 testing data:

[0099] No. Test item Standard requirement Inspection result 1 Thermal conductivity / W / (m·K) ≤0.040 0.036 2 Volume water absorption ≤5.0 3.4 3 Acidity coefficient ≥1.8 1.97 4 Compressive strength ≥40 42 5 Tensile strength perpendicular to the surface ≥10 10.6

[0100] It can be seen that the rock wool material of the present embodiment has excellent performance, and the performance testing results meet the standard requirements.

[0101] The rock wool material of the present embodiment is selected to prepare a rock wool product, and an adsorption experiment is performed. During the preparation of the rock wool product, the emission of pollution gas per cubic meter cannot exceed the limit value. In the production process of rock wool, especially in the step of curing phenolic resin at 150 DEG C, harmful gases including formaldehyde and phenol with high concentration can be generated. Taking the rock wool formula of example 3 as an example, 7.2 kg of phenolic resin is required for the production of 100 kg of rock wool. Under this condition, the concentration of formaldehyde in the harmful gas generated during production is measured to be 163 micrograms per cubic meter, and the concentration of phenol is measured to be 0.0031 micrograms / m 3 According to the environmental protection requirements, 3.5 kg and 5.0 kg of adsorption functional additives are added to every hundred kilograms of rock wool production raw materials, respectively. The ratio of activated carbon and organic bentonite DK4 is 3:1, that is, the production formula of adsorptive rock wool is shown in Table 4.

[0102] Table 4: Adsorption experiment formula:

[0103] Material name Formulation 3 Formulation 4 Formulation 5 Rock wool production raw material 100 100 100 Phenolic resin adhesive 7.2 7.2 7.2 Adsorptive functional adjuvant 3.5 5.0

[0104] In each formula, the rock wool generating raw material is the rock wool material formula in the above-mentioned example 3. After the adsorption experiment, the experimental data is shown in table 5.

[0105] Table 5: Adsorption experiment data

[0106]

[0107] From the above data, it can be seen that the addition of adsorption functional additives has a very obvious reducing effect on reducing harmful gases generated in production. The adsorption capacity of the added adsorbent far exceeds the amount of organic harmful gases generated in production. After the rock wool insulation board and the rock wool sound-absorbing board material are installed, the rock wool board with such a composite function can continue to adsorb harmful gases such as formaldehyde generated in the working and living environment, thereby ensuring the health of people.

[0108] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited to this. Any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present application, which should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A rock wool material, characterized in that, The raw materials of the rock wool material, by weight, include: Red mud 15-25 parts, fly ash alumina extraction residue A 5-10 parts, fly ash alumina extraction residue B 10-26 parts, kaolinite 20-46 parts, calcium carbide slag 18-28 parts, wollastonite 5-15 parts. The red mud contains less than 3% iron oxide and has a pH of 7-9; the fly ash alumina extraction residue A contains less than 5% alumina and has a pH of 8-10, and the main chemical component of the fly ash alumina extraction residue A is active calcium silicate, with a content of 60-70%; the main chemical component of the fly ash alumina extraction residue B is silicon dioxide, with a silicon dioxide content of more than 90%.

2. The rock wool material according to claim 1, characterized in that, The acidity coefficient (SiO2+Al2O3) / (CaO+MgO) of the mixture of red mud, fly ash extracted alumina residue A, fly ash extracted alumina residue B, kaolinite, carbide slag, and wollastonite is greater than 1.

5.

3. A rock wool product, characterized in that, The raw materials for preparing the rock wool products include the rock wool material as described in claim 1 or 2, as well as phenolic resin binder and adsorbent components; The mass ratio of the rock wool material, phenolic resin binder, and adsorbent components is 100:(7-7.5):(3.5-5.0).

4. The rock wool product according to claim 3, characterized in that, The raw materials of the phenolic resin adhesive include, by weight, the following: 90-110 parts phenolic resin, 10-20 parts expanded perlite, 5-15 parts cenospheres, 0.1-0.15 parts silane coupling agent KH602, 0.1-0.15 parts alcohol, and 0.5-1.0 parts wetting and dispersing agent.

5. The rock wool product according to claim 4, characterized in that, The floating beads are hollow fly ash.

6. The rock wool product according to claim 3, characterized in that, The adsorbent components include activated carbon adsorbent and organic bentonite adsorbent; the particle size of the activated carbon adsorbent and organic bentonite adsorbent is not less than 200 mesh, and the interlayer spacing of the organic bentonite adsorbent is 3.5-4.0 nanometers.

7. A method for preparing a rock wool product as described in any one of claims 3 to 6, comprising the following steps: Step 1. Red mud, fly ash extracted alumina residue A, fly ash extracted alumina residue B, kaolinite, carbide slag and wollastonite are mixed under high temperature and then melted to obtain the rock wool material. Step 2. The rock wool material is subjected to high-speed centrifugal spinning and then cooled and shaped to obtain inorganic cotton; Step 3. Spray the phenolic resin adhesive onto the surface of the shaped inorganic cotton according to the mass ratio to further shape it; Step 4. Add the adsorbent components to the inorganic cotton that has been further shaped in Step 3 according to the mass ratio, and then dry it at high temperature after applying the pendulum method and three-dimensional cotton laying method. Finally, cut it to obtain the rock wool product.

8. The method for preparing rock wool products according to claim 7, characterized in that, The process of preparing the rock wool material in step 1 includes: (1) First, the red mud, fly ash alumina extract residue A, fly ash alumina extract residue B, kaolinite, and wollastonite are mixed together until they are evenly mixed to obtain a premix. (2) The calcium carbide slag is fed into an electric furnace and the temperature is controlled between 550-600℃ to completely decompose calcium hydroxide into calcium oxide and water vapor. (3) The premixed material is put into the electric melting furnace and the temperature is controlled between 1500-1600℃ so that the mixture is fully melted in the electric melting furnace to obtain the rock wool material.

9. The method for preparing rock wool products according to claim 7, characterized in that, The preparation process of the phenolic resin adhesive includes: (1) Mix alcohol and silane coupling agent KH602 in a mass ratio of 1:1 to obtain an alcohol solution of silane coupling agent KH602; (2) Place the expanded perlite and cenospheres into a high-speed stirring device, add the alcohol solution of the silane coupling agent KH602, and start stirring for 2-3 minutes. (3) Take out the processed expanded perlite and cenospheres and air dry them in the air for 1 hour to allow the alcohol to evaporate completely; (4) The phenolic resin, wetting and dispersing agent, and the treated expanded perlite and floating beads are put back into the high-speed mixing equipment for mixing for 3-5 minutes to obtain the phenolic resin adhesive.

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